Process for removing contaminants from gas streams

ABSTRACT

The present invention provides for process for inhibiting the levels of nitrogen oxides in process gas streams from sulfuric acid regeneration and production plants. The process gas stream from the waste heat boiler and the candle mist eliminator is contacted with ozone which will react with nitrogen oxides present in the flue gas.

The present application is a Continuation-In-Part of U.S. application Ser. No. 11/971,948 filed Jan. 10, 2008 which claims priority from U.S. Application No. 60/897,003 filed Jan. 23, 2007.

BACKGROUND OF THE INVENTION

The present invention provides for processes for removing contaminants from gas stream emissions. More particularly, the present invention provides for removing contaminants such as nitrogen oxides from gas streams in sulfuric acid production processes.

Sulfuric acid is used in a wide spectrum of process industries. Sulfuric acid is believed to be the world's largest chemical produced. Over past few decades, worldwide, most of the sulfuric acid is produced by a contact process, which involves generating a sulfur dioxide containing gas stream from variety of sulfur sources. Examples include burning elemental sulfur, or process of roasting metal ore or burning H₂S arising from industrial operations such as hydrodesulfurization of petroleum products or simply burning waste containing sulfate or sulfuric acid or combusting spent sulfuric acid all generate SO₂ in the gas stream. If the source of sulfur is dirty, flue gas is conditioned and oxidized to convert almost all SO₂ to SO₃ over a V₂O₅ catalyst in a multi pass converter. The oxygen required for oxidation is either present or supplemented in the form of additional air or oxygen. This SO₃ containing gas stream is absorbed in sulfuric acid solution, which results in the H₂SO₄ product as a >95% wt acid or oleum of desired strength.

Since sulfuric acid is a very low cost product, and reactions are exothermic, heavy emphasis is put on heat integration and therefore generally most exothermic heat that is recovered is used within the process for captive requirement of energy and any net surplus is exported in the form of steam. Nitrogen oxides (NO_(x)) are generally formed during the SO₂ generation step in varying quantities based on a variety of factors. When an SO₃ containing gas stream is absorbed into sulfuric acid solution, some of the NO_(x) reacts with a circulating solution of sulfuric acid forming a complex which is referred in industry as niter (nitrosyl sulfuric acid) and some of its homologs. Niter in the product is an undesirable impurity in many applications and also imparts some color to the product.

Some of the NO_(x) which leaves the scrubber passes through much of the process equipment and is finally exhausted to the environment. It is often noted that the plume arising from the sulfuric acid production facility is correlated with SOx emissions, NO_(x) emissions, niter, types of mist eliminating devices and various process parameters. Some of these environmental problems are alleviated in the modern plant by a dual stage absorption process, choosing effective mist elimination devices followed by a caustic scrubber. Selective catalytic reduction (SCR), selective non-catalytic reduction (SNCR) type of processes have been suggested for NO_(x) removal. However, the problems of NO_(x) emissions, acid plume, deterioration of product quality due to niter and nitrogen containing compounds in sulfuric acid still exists at varying levels in the industry. With increasing environmental concern and government oversight, the present levels of NO_(x) controls are not adequate.

Sulfuric acid is a high production volume but a low cost and low margin chemical. The cost of a plant producing sulfuric acid is relatively high. The relationship of the capital cost and the plant capacity is not linear. Therefore, plants with a larger production capacity achieve much better scales of economy compared to plants with smaller capacities. Sulfuric acid is a highly reactive chemical and therefore transporting it over long distance is not only expensive but also increasingly hazardous. For a smaller plant operator, it makes good economic sense to boost the capacity of sulfuric acid by employing oxygen enrichment in the SO₂ generation and or oxidation stage.

Oxygen enrichment when done to the SO₂ generation stage, not only increases throughput, but also can improve thermal efficiency thereby reducing fuel requirements, increasing SO₂ concentration in the process gas stream, and exporting more steam and reducing unit product cost. Replacing some of the combustion/oxidation air with gaseous oxygen not only improves capacity of the furnace but also increases SO₂ content of the process gas stream exiting the furnace. Generally downstream equipment such as catalytic converters, waste heat recovery equipment, fans, etc. operate more effectively at higher concentration of SO₂ and lower process gas flow rates. Typical sulphuric acid processing equipment has adequate processing capacity to handle 30 to 40% additional SO₂ load. In the case when SO₂ is arising from a metal roasting furnace, oxygen enrichment not only improves sulfuric acid throughput but also enhances ore processing capacity.

With all these positive aspects of oxygen enrichment with respect to capacity and costing, there is a major down side. Oxygen enrichment produces higher combustion temperatures in the furnace with greater O₂ concentration resulting in higher amount of NO_(x) formation. Without addressing issues regarding higher environmental emissions and increased niter content of the product, full potential or benefits of oxygen enrichment can not be achieved. FIG. 1 depicts the difficulty in economically justifying smaller size plants due to longer payback period. However with O₂ enrichment, this payback period can be significantly reduced.

SUMMARY OF THE INVENTION

The present invention provides for a method for removing contaminants from a waste gas stream in a sulfuric acid production process comprising the steps:

-   -   a) contacting said waste gas stream with ozone;     -   b) directing said waste gas stream to a particulate scrubber;     -   c) directing said waste gas stream to a gas dryer; and     -   d) recovering said waste gas stream.

The present invention also provides for a method for removing contaminants from a gas stream from a candle mist eliminator in a sulfuric acid production process comprising the steps:

-   -   a) contacting said gas stream with ozone;     -   b) directing said gas stream to an environmental scrubber; and     -   c) recovering said gas stream.

The present invention further provides for a method for producing sulfuric acid comprising the steps:

-   -   a) recovering a gas stream from a sulfuric acid recovery         furnace;     -   b) directing said gas stream to a particulate scrubber;     -   c) injecting ozone into said gas stream prior to it entering         said particulate scrubber;     -   d) directing said scrubbed gas stream to a gas drying tower;     -   e) directing said dried, scrubbed gas stream to a catalyst bed         to convert sulfur dioxide present in said dried, scrubbed gas         stream to sulfur trioxide;     -   f) directing said gas stream containing sulfur trioxide to a         sulfuric acid absorption tower; and     -   g) recovering sulfuric acid.

The invention relates to de-bottle-necking capacity of sulfuric acid production plant particularly when SO₂ gas is derived from sources other than elemental sulfur. Examples of SO₂ gas derived from sulfur sources are:

Metal ore processing furnace where SO₂ is produced as a result of the reaction between Metal sulfide and Oxygen.

MS+2 O₂→MO₂+SO₂

H₂S generated by refinery processes

2 H₂S+3 O₂→2 SO₂+2 H₂O

Sulfate containing waste or spent sulfuric acid furnace

SO₄→SO₂+O₂

2 H₂SO₄→2 SO₂+2 H₂O+O₂

The spent sulfuric acid stream is generally weak or contaminated sulfuric acid which often has water and some by-products of the main reaction and needs to be purged. One of the major sources of spent sulfuric acid is the alkylation process of refinery gas where C₄ (butenes, isobutenes) containing gas stream is subjected to an alkylation reaction to produce iso-octane containing petroleum feedstock. Other important processes that use sulfuric add are esterification, nitration, oxidation, and sulfonation of organic molecules. Some specific examples where the spent sulfuric acid stream is purged in manufacturing are production of oxalic acid, Nylon 66 (adipic acid), and dioctyl, diethyl, dimethyl pthalates, etc.

Although theoretically most of the spent sulfuric acid can be regenerated, economically it makes sense to recover sulfuric acid from streams that are generated in large quantities with low water content; especially where cheaper means of disposal or treatment are not viable or practical.

There are a number of methods to remove, reduce and prevent NO_(x) formation in sulfuric acid regeneration and production systems. Most of these methods are either not very effective, are capital intensive, complicated and/or require significant amount of energy.

The present invention provides for a novel approach to removal of NO_(x) at two different locations based on the required needs of the plant operator. If the primary need is to reduce niter content of the product sulfuric acid, the first option is more suitable and if the NO_(x) in the flue gas in the stack is the concern, the second option may be an optimal choice.

In both options, ozone is injected into the gas stream in a ratio of about 0.5 to about 3.0 molar ratio of ozone to NO_(x) to oxidize insoluble NO_(x) to highly soluble oxides of nitrogen.

NO+O₃→NO₂+O₂

NO₂+O₃→NO₃+O₂

NO₃+NO₂=N₂O₅

N₂O₅ is very soluble compared to NO₂ and NO and therefore can be very easily scrubbed with water.

N₂O₅+H₂O→2 HNO₃

Ozone is generated on site and as needed by using either an up to 25 psig dry instrument air to produce 2.7% by wt ozone or 93% or higher purity oxygen to produce 10% by wt or higher concentration ozone.

In the second option, the environmental scrubber not only removes NOx, but also is intended to remove unconverted SO₂. Therefore, the scrubbing solution consists of sodium hydroxide or carbonate solution. Absorption of SO₂ in the sodium carbonate or hydroxide solution forms sodium sulfite and bisufite in situ.

SO₂+NaOH→NaHSO₃

NaHSO₃+NaOH=Na₂SO₃+H₂O

The presence of sulfite is essential in Option 2 to deplete excess ozone if NOx concentration in the treated gas stream is to be reduced below 20 PPM by volume. Unreacted ozone in the scrubber is depleted in the following reaction:

Na₂SO₃+O₃→Na₂SO₄+O₂

In addition to Ozone oxidizing Sulfite, oxygen present in the gas stream also oxidizes sulfite in the scrubbing solution to sulfate.

2 Na₂SO₃+O₂→Na₂SO₄

NO₂ in the gas stream also is known to deplete sulfite in the aqueous stream. Therefore, if ozone emission via the treated gas stream to the stack is a concern, supplementary sulfite may be added to the environmental scrubber. Sodium thiosulfite or reduced sulfur may be added in the environmental scrubber to maintain the required level of sulfite for depletion of ozone.

In a further embodiment of the invention, ozone is introduced into the sulfuric acid process by a different means. The first location that ozone is introduced is downstream of the sulfur dioxide generation furnace and prior to entering the particulate scrubber. In the present embodiment, ozone is introduced after the sulfur dioxide generation furnace and in the particulate scrubber. Consequently, the ozone is added to the waste gas stream at a temperature of less than about 100° C.

The invention is a method for removing contaminants from a waste gas stream in a sulfuric acid production process comprising the steps:

-   -   a) directing the waste gas stream to a particulate scrubber;     -   b) contacting the waste gas stream with ozone;     -   c) scrubbing oxidized NOx in the particulate scrubber;     -   d) directing the waste gas stream to a gas dryer; and     -   e) recovering the waste gas stream.

The invention further is a method for producing sulfuric acid comprising the steps:

-   -   a) recovering a gas stream from a sulfuric acid recovery         furnace;     -   b) directing said gas stream to a particulate scrubber;     -   c) injecting ozone into the gas stream in the particulate         scrubber;     -   d) scrubbing oxidized NO_(x) in the particulate scrubber;     -   e) directing the scrubbed gas stream to a gas drying tower;     -   f) directing the dried, scrubbed gas stream to a catalyst bed to         convert sulfur dioxide present in the dried, scrubbed gas stream         to sulfur trioxide;     -   g) directing the gas stream containing sulfur trioxide to a         sulfuric acid absorption tower; and     -   h) recovering sulfuric acid.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graph representing plant capacity versus years to recovery for capital cost.

FIG. 2 is a graph showing the increase in NO_(x) and niter as oxygen content in the feed increases.

FIG. 3 is a schematic representation of a sulfuric acid regeneration (SAR) process integrated with the NO_(x) reduction schemes per the present invention.

FIG. 4 is a graph representing the increase in revenue versus capacity increase in oxygen enrichment.

FIG. 5 is a more detailed schematic of the particulate scrubber of FIG. 3.

DETAILED DESCRIPTION OF THE INVENTION

A Sulfuric Acid Regeneration (SAR) plant and acid recovery system on a metal ore roaster furnace is a slightly modified form of a sulfur burning sulfuric acid plant. In all three types of plants, a source of sulfur is converted to SO₂ in the process gas. In the first two types of plants, SO₂ containing streams have particulate matter and other acidic contaminants and need to be washed and dried prior to oxidizing to SO₃. The clean and dry SO₂ containing stream is passed through a series of heat exchangers and beds of V₂O₅ catalyst to convert it to SO₃ at about 450 to 550° C. Typically 3 to 4 catalyst beds called converters are used. The heat from the process gas stream exiting the final converter bed is used in heating the gas entering the converter by series of cascaded heat exchanger. SO₃ is absorbed in the sulfuric acid absorber to form oleum or 98% sulfuric acid and some product is continuously removed.

In the newer sulfuric acid plants, the flue gas stream from the absorber is again heated and passed through a V₂O₅ bed to oxidize residual amounts of SO₂ and then subjected to another absorber to remove almost all of sulfur as SO₃. The exhaust gas from the 2nd absorber is passed through a candle mist eliminating device to remove H₂SO₄ mist and finally scrubbed with caustic soda in an environmental scrubber before exhausting through the stack. Environmental scrubbers are not always employed and mostly configured in the train to meet the local regulations governing SO₂ emissions.

The main difference between a traditional sulfur burning sulfuric acid and an acid recovery or SAR unit is how the sulfur source is converted to SO₂. A SAR unit as shown in FIG. 3 uses a furnace to convert spent sulfuric acid to SO₂. Since decomposition of H₂SO₄ is endothermic and favored by raising the temperature, natural gas or hydrocarbon feedstock is required to raise temperature of the furnace. Generally finely atomized sulfuric acid is held at 650° C. or higher for a sufficient time to obtain 99.5% conversion. A supplemental feed stream of H₂S can be fed to this furnace for three primary reasons, 1) H₂S has a calorific value 2) it is a good source of sulfur and 3) there is a monetary benefit in taking care of H₂S. The exhaust from SAR furnace, in addition to SO₂, has other contaminants, such as fly ash, etc. After recovering the heat in the waste heat boiler, the exhaust gas is around 130° C. to 250° C. This process gas is subjected to an aqueous wash to remove particulate matter, fly ash and other impurities. The gas is then dried by scrubbing with sulfuric acid and forwarded to a series of heat exchangers and converters.

In a conventional sulfuric acid plant, molten elemental sulfur is burnt in a furnace to form sulfur dioxide. In contrast to SAR, SO₂ produced from elemental sulfur is relatively free from dust, fly ash and other contaminants and does not require “washing” or scrubbing. The SO₂ containing gas stream from the furnace can be directly led to series of waste heat boilers, converters and heat exchangers. Therefore sulfur burning sulfuric acid plants export as much as 1.4 tons of steam per ton of sulfuric acid produced.

Some NO_(x) is always produced in furnaces where SO₂ is generated. The sulfuric acid decomposition reaction in the SAR process, in particular, is favored by higher furnace temperature which in turn causes some of the nitrogen to convert to nitric oxide in the furnace. Some organic nitrogen content in the spent sulfuric acid converts to nitric oxide in the furnace. To assure adequate destruction of organic contamination in spent sulfuric acid, a certain residence time is required at furnace temperature. To increase SAR unit throughput (up to 30%) the furnace is often supplemented with pure oxygen stream. All these lead to formation of NO_(x) in the furnace.

NO_(x) formed consists mainly of NO and NO₂. Both nitric oxide (NO) and nitrogen dioxide (NO₂) are sparingly soluble gases. They are not significantly removed in the particulate scrubbers and pass along with process gas through converters to the sulfuric acid absorber. Some of the NO reacts with the sulfuric acid and forms nitrosyl sulfuric acid “niter” and imparts a violet coloration to the sulfuric acid product. Industrial sulfuric acid users are sensitive to concentrations of “nitrogen” or “niter” in the sulfuric acid. The exhaust from the sulfuric acid absorber still has an equilibrium concentration of NO, some of which further condenses in the candle mist eliminator as niter. Finally the remainder of NO exits the sulfuric acid plant with exhaust gas which is emitted to the atmosphere via the stack.

In order to increase the production capacity in the existing SAR furnace or metal ore kiln, the feed air can be supplemented with oxygen. FIG. 2 depicts the effect of O₂ enrichment on stack emissions and product quality. As shown in FIG. 2 with an increase in O₂ concentration in the feed, NO_(x) content in the flue gas through stack rapidly increases and so does the niter content of the product acid.

Therefore it is very likely that the enrichment that provides up to 30% more throughput can cause issues with the environment and product quality. In addition, although exact reasons are not known but higher niter content in the product acid is also associated with visible plume at the stack.

Many geographical regions in the United States such as the North-East, Houston-Galveston and California regions fall under ozone non-attainment area rules and regulations. The control of NO_(x) emissions is a primary concern for local, state and federal environmental protection authorities.

The Clean Air Act of 1990 and the Interstate Air Quality Rules (IAQR) mandate the USEPA, state and local air-quality management authorities to implement tougher standards to improve air quality. Most existing refineries that generate spent sulfuric acid are on the east coast, gulf coast and along the west coast of the United States. The amount of spent sulfuric acid generated by an individual refinery is not large enough for an economically viable SAR unit. Therefore a separate unit that can process spent sulfuric acid streams from more than one refinery is more preferable. Such a unit becomes a new and independent source and therefore is outside the bubble permit of any one refinery.

Sulfuric acid is a very low value commodity and is hazardous cargo to haul. There is also increasing pressure on refineries to reduce sulfur content of liquid fuels (diesel). It is therefore of interest to set up a spent sulfuric acid plant in the vicinity of refineries where spent and product sulfuric acid can be exchanged via pipeline. In addition, SAR units can also advantageously process additional amounts of H₂S generated by these refineries. However, such a location as mentioned above invites close scrutiny in environmental permitting and mandates industry to pursue gas pollution control devices that meet MACT standards.

Turning to FIG. 3, a furnace A is fed through line 1 with fuel gas. Spent acid is fed through line 2 and oxygen and hydrogen sulfide are fed through lines 3 and 4 respectively. Waste gas from the furnace A will leave through line 13 and enter waste heat boiler B. Steam from the waste heat boiler B will exit through line 15. The cooler waste gas exits waste heat boiler B through line 14 and enters air heater C which is fed air through line 5. Hot air from the air heater C will also be directed through line 1A into line 1 for the fuel gas being fed to the furnace. In an alternate configuration lines 3 and lines 4 can be also directed into line 1.

The waste gas stream will leave air heater C through line 16 and be directed into the particulate scrubber D. The first option of the present invention begins here with the introduction of ozone through line 12 such that the waste gas stream and ozone are mixed together prior to the waste gas stream entering the particulate scrubber D. If the waste gas temperature entering the particulate scrubber D exceeds 135° C., flue gas may be quenched prior to mixing with ozone. The scrubbed gas stream will exit the particulate scrubber through line 18. The scrubbing solution is pumped out of particulate scrubber D through pump 17 and directed into the spray header assembly through line 17A.

The wet gas stream in line 18 has air injected into it through line 6 and this stream now enters the gas drying tower E. The solution used in the gas drying tower E (generally H₂SO₄) is pumped out through pump 19 and reenters the tower via liquid distributor through line 19A. Some circulating H₂SO₄ from this tower is exchanged with Sulfuric Acid absorption tower J. This circuit is not depicted in the diagram. Dry gas leaves the gas drying tower E through line 20 and this gas stream is at about 65° C. This dry gas stream will enter a series of heat exchangers, in this example F, G and H respectively through line 20 before entering the converter I. Converter I has through separate converters present therein containing catalytic materials which will convert the clean and dry sulfur dioxide gas stream entering the converter I into sulfur trioxide.

The sulfur trioxide generated by the catalytic conversion will exit the converter I through line 23 and be directed to the first heat exchanger H where it will be cooled and reenter the converter I at a point lower than when it was removed. The same holds true with sulfur trioxide withdrawn through line 22 where it will enter the second heat exchanger G and reenter the converter I at a point lower than where it was removed. Lastly the converted sulfur trioxide is withdrawn from the bottom of the converter I through line 21 and will pass through the third heat exchanger before it enters the sulfuric acid absorption tower J. The heat exchange system may also have the provision to produce steam. Oxidation of SO₂ to SO₃ is highly exothermic and occurs at high temperatures in industrial applications. Normal practice is to carry it out in the temperature range in excess of 425° C. There are many configurations practiced in meaningful recovery and use of heat. The present invention is applicable to all the configurations. For the sake of brevity we have described only one of them in this example.

Sulfuric acid is fed into the sulfuric acid absorption tower through line 7 and the absorbing solution will exit through pump 24 through line 24A which feeds the absorbing solution into the liquid distributor at the top of the sulfuric acid absorption tower J. Oleum or sulfuric acid as product is withdrawn through line 8. The gas stream which has much of its sulfuric acid content removed will leave the absorption tower J through line 25 and enter the final heat exchanger K before entering the final converter L. The final converter L will contain catalytic material which will again convert any residual sulfur dioxide into sulfur trioxide.

The gas stream exiting the converter which now contains little sulfur dioxide is directed through line 26 into the final sulfuric acid absorption tower M. Sulfuric acid is circulated into this tower. The scrubbing solution (sulfuric acid) is recovered through pump 9A and fed back to the liquid distributor through line 9B. Some sulfuric acid (product) is also withdrawn from 9A via line 10. A sulfuric acid solution is added to absorption Tower M through line 9. The scrubbed gas will leave the final sulfuric acid absorption tower through line 28 and will enter the candle mist eliminator N. The candle mist eliminator N will contain mesh or other gas filtering devices to separate the gas mixture entering the eliminator which contains sulfur dioxide, some sulfuric acid, nitrogen oxides, carbon dioxide and oxygen and nitrogen. The residual sulfuric acid which is separated from the gas mixture will leave the candle mist eliminator through pump 29 and be directed into feed line 10. Sometimes, the collection from the mist eliminator is not mixed with the product acid (in line 10) and separately processed as it may have higher concentration of niter.

The separated gas stream which still contains nitrogen oxides will leave the candle mist eliminator N through line 30. Ozone is injected into this line through line 12A so that it mixes with the gas stream containing the nitrogen oxides before entering the environmental scrubber O. The ozone injection spot in the line 30 is so chosen as to provide adequate residence time for ozone to mix and oxidize NO_(x) prior to entering the Scrubber O. Ozone is injected via nozzle(s) or perforated tube to ensure thorough mixing within bulk of the gas stream.

In the scrubber O the solution will scrub the nitrogen oxides and sulfur oxides remaining in the gas mixture. Scrubber solution is drawn from the environmental scrubber O through pump 31 and bled from the system through scrubber bleed line 11. What solution is not bled off is directed back into the environmental scrubber O into its spray headers through line 31A. The gas that is now substantially free of nitrogen oxides and sulfur oxides will leave the environmental scrubber O through line 32 to be directed to the stack. The pH of the environmental scrubber is maintained by feeding caustic soda or alkaline carbonates which is not depicted in the figure.

When SO_(x), present in the line 30 is low, sulfite generated in-situ in the environmental scrubber O may not be enough to deplete the unreacted ozone. A small feed of sodium sulfite, thiosulfate or reduced sulfur may also be fed to maintain sulfite concentration in the environmental scrubber necessary to deplete ozone.

The first inventive option is to treat the process gas exiting the waste heat boiler downstream of the SAR furnace at a low temperature (preferably less than 132° C.) to selectively oxidize NO_(x) to higher water soluble oxides such as N₂O₅, which reacts with moisture in the flue gas to form nitric acid. Extensive testing at various facilities has indicated this technology does not oxidize SO₂ to generate any measurable amount of SO₃. The wet scrubber to remove fly ash and other particulate matter in the process gas stream also removes this oxidized form of NO_(x), namely N₂O₅ and nitric acid. This option produces an SO₂ containing process gas that is substantially free from NO_(x). Therefore, if this alternative is elected, the sulfuric acid product will not contain objectionable quantities of niter or nitrosyl sulfuric acid. Since an excess of ozone in the process flue gas stream is of little consequence in SAR processes, NO_(x) levels as low as 2 ppm can be maintained with proper engineering and process controls. If the quencher is used to reduce temperature of the flue gas, care must be taken to reduce or minimize water droplets in the ozone oxidation zone.

The second inventive option is to treat the process flue gas exiting the candle mist eliminator. The SO₂ content of the flue gas varies from 50 to 2000 PPM depending on the plant design. This flue gas also contains some sulfuric acid mist, between 10 to 1000 ppm of NO_(x), 4-12% CO₂, and the remainder oxygen and nitrogen. NO_(x) can be selectively oxidized to N₂O₅ and nitric acid vapor by mixing ozone into the flue gas. An environmental scrubber with aqueous solution of caustic soda or alkaline carbonate/bicarbonate recirculation can reduce substantially both SO_(x) and NO_(x) at the same time prior to exhausting flue gas to the stack. To neutralize nitric acid, there will be a slight increase in the consumption of scrubber alkali.

Both options depicted above are capable of delivering a wide range of desired NO_(x) removal efficiencies with large variations in process conditions and irrespective of increase in feed nitrogen oxides or load swings. Accordingly, the present invention can be used either to treat process or flue gas for quality/environmental compliance (first option) or solely for environmental compliance (second option).

As seen in the above example, there is no new equipment to be added and existing equipment can be modified or retrofitted with O₃/O₂ injection skid.

The cost impact of such a NO_(x) control solution is a small fraction of the benefit that could be achieved by O₂ enrichment.

FIG. 4 depicts a clear representation of incremental revenue due to capacity enhancement including increased operating costs.

It is known that at temperatures exceeding 100° C. and particularly 130° C. that the performance of ozone oxidation significantly deteriorates. The ozone molecule itself decomposes to oxygen at these higher temperatures. In order for ozone to be well mixed with the bulk of the gas stream to be treated and to ensure reaction with NO_(x), ozone must be introduced upstream of the particulate scrubber to provide the necessary mixing and reaction time. At the higher temperatures above 130° C., reaction times are relatively extremely short. Mixing times in industrial size equipment becomes large and is a leading factor in poorer performance at higher gas stream temperatures.

Of further concern is the presence of high concentrations of sulfur dioxide at elevated temperatures. Oxidation reactions between sulfur dioxide and higher oxides of nitrogen become important as the more soluble higher oxides of nitrogen are wastefully consumed in oxidizing sulfur dioxide. This is seen in the following equations:

SO₂+NO₃→SO₃+NO₂

SO₂+N₂O₅→SO₃+2NO₂

NO₂ solubility is an order of magnitude lower than either N₂O₅ or NO₃ and limits NO_(x) removal in the particulate scrubber by wet scrubbing. Therefore, introducing ozone upstream of a particulate scrubber in a very high concentration, hot sulfur dioxide stream, typically found in sulfuric acid processes is not a simple and attractive option. As noted above, in the absence of quenching the temperature to below 135° C., ozone consumption is higher, nitrogen oxides removal is lower and formation of SO₃ upstream of the particulate scrubber are all concerns.

Alternatively, oxidation of nitrogen oxides in the particulate washing stage rather than upstream can be achieved. In a typical particulate scrubber, a hot sulfur dioxide containing gas stream is contacted with an aqueous stream in the form of a spray of an aqueous medium in a co-current or counter-current manner. Another commonly practiced approach is to contact gas with liquid in a converging conical section of a venturi scrubber. The particulate matter is washed from the gas stream and will go along with the liquid phase. Following the gas-liquid contacting stage, there is disengagement of liquid droplets from the gas stream. Sometimes this step will be followed by a final washing stage. In all of these gas-liquid contacting devices for particulate scrubbing, gas almost always gets quenched at the first stage of the gas-liquid contact due to the temperature of the incoming gas stream.

The improvement comprises adding ozone after the initial particulate scrubbing stage at a suitable location in the droplet disengagement zone. The temperature in this zone is below 100° C. and suitable for effective nitrogen oxides oxidation with ozone. Higher oxides of Nitrogen (including N₂O₅) react readily in gas phase with water vapor forming oxy acids of nitrogen.

Therefore, at this lower temperature, the problem of sulfur dioxide oxidation with higher oxides of nitrogen is alleviated.

Further no change in the initial gas-liquid contacting in the particulate removal scrubber will need to occur allowing for continued effective particle removal. This method will also allow retrofitting to existing installations by injecting ozone into existing particulate scrubbers at a suitable injection point location.

Referring to FIG. 3, the waste gas stream will leave air heater C through line 16 and be directed into the particulate scrubber D. FIG. 5 enhances details of scrubber D for the purpose of clarity. Referring to FIG. 5, ozone is introduced by line 12B into the disengagement zone such that the waste gas stream and ozone are mixed together prior to entering final washing stage of the particulate scrubber D. In the final washing stage, waste gas is subjected to final washing and NOx along with the remainder of particulate matter is scrubbed. The temperature of the waste gas stream will be below 100° C. in the disengagement zone where ozone is mixed. As such, no separate quencher is required for lowering the waste gas stream temperature upstream of the particulate scrubber D. The scrubbed gas stream will exit the particulate scrubber D through line 18 the scrubbing solution is pumped out of the particulate scrubber D through pump 17 and directed into the spray header assembly through line 17A for primary wash and 17B for final wash. The remainder of the operation is similar to that described earlier with reference to the first treatment option and FIG. 3.

In this process, it can be seen that the nitrogen oxides oxidation chemistry is supported by this method.

NO+O₃→NO₂+O₂

NO₂+O₃→NO₃+O₂

NO₃+NO₂→N₂O₅

N₂O₅+H₂O (vapor)→2 HNO₃ (vapor)

N₂O₅ and HNO₃ are very soluble compared to NO₂ and NO and therefore is easily scrubbed with water in the final wash section:

N₂O₅+H₂O (liquid)→2 HNO₃ (liquid)

HNO₃ (vapor)→HNO₃ (liquid)

There will be slightly more ozone consumption due to the presence of small droplets in the disengagement zone. SO₂ dissolves in the aqueous droplets forming weak sulfurous acid which is known to consume ozone:

SO₂+H₂O⇄H₂SO₃

H₂SO₃→H₂SO₄+O₂

However, if ozone is uniformly and quickly mixed in the bulk of gas phase in the disengagement zone at a suitable location where droplets are minimal, then the ozone oxidation reaction with nitrogen oxides will be fast and occur in the homogeneous gas phase. This is contrasted with the reaction in the sulfurous acid occurring in the liquid phase where ozone first has to be transported from bulk of the gas phase to the liquid phase. Therefore, nitrogen oxides oxidation will favorably compete with sulfurous acid oxidation with ozone. Higher order nitrogen oxides in the presence of very high water vapor content transform readily into highly soluble oxy acids in the homogeneous gas phase improving NOx absorption in the final washing stage.

This process will use higher ozone to nitrogen oxides ratio to reduce the residence time requirements for nitrogen oxides oxidation reaction. Less residence time in the disengagement zone reduces both the amount of liquid droplets that the gas encounters and the time in which liquid droplets come in contact with the gas thereby reducing wasteful ozone consumption in the liquid phase.

There are no process issues with excess ozone being carried downstream of the particulate scrubber at this point in the process. Commercially available particulate scrubbers such as Dynawave available from MECS or EDV available from Belco Technologies can be used with this process. In order to locate minimal entrained droplet zone, some minor changes in the configuration or commonly available particulate scrubbers may be necessary.

While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of the invention will be obvious to those skilled in the art. The appended claims in this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the invention. 

1. A method for removing contaminants from a waste gas stream in a sulfuric acid production process comprising the steps: a) directing said waste gas stream to a particulate scrubber; b) contacting said waste gas stream with ozone; c) scrubbing oxidized NO_(x) in said particulate scrubber; d) directing said waste gas stream to a gas dryer; and e) recovering said waste gas stream.
 2. The method as claimed in claim 1 wherein said waste gas stream is from a waste heat boiler and other waste heat recovery equipment.
 3. The method as claimed in claim 1 wherein said ozone is injected into said waste stream in a molar ratio of about 0.5 to 3.0 ozone to nitrogen oxides.
 4. The method as claimed in claim 1 wherein said ozone is injected at a pressure of up to 25 psig and ozone is up to 10 weight percent in oxygen.
 5. The method as claimed in claim 1 wherein said waste gas stream contains sulfur dioxide, nitrogen oxides, fly ash, particulates and other acidic contaminants.
 6. The method as claimed in claim 1 wherein said ozone converts said nitrogen oxides to N₂O₅ and nitric acid.
 7. The method as claimed in claim 1 wherein said particulate scrubber removes said fly ash, particulates, N₂O₅, nitric acid and other acidic contaminants from said waste gas stream.
 8. The method as claimed in claim 1 wherein said gas dryer removes water from said waste gas stream.
 9. The method as claimed in claim 1 wherein said recovered waste gas stream is directed to a catalyst bed and sulfuric acid absorption tower.
 10. The method as claimed in claim 1 wherein said waste gas stream is at a temperature of 100° C. or less.
 11. The method as claimed in claim 1 further comprising injecting oxygen into a furnace of said sulfuric acid production process.
 12. The method as claimed in claim 1 wherein said ozone contacts said waste gas stream in said particulate scrubber.
 13. The method as claimed in claim 12 wherein said ozone contacts said waste gas stream in a disengagement zone of said particulate scrubber
 14. The method as claimed 1 comprising washing said waste gas stream in said particulate scrubber.
 15. The method as claimed in claim 1 wherein primary particulate wash, contacting with ozone and final particulate wash and nitrogen oxides scrubbing are all performed in at least one vessel.
 16. A method for producing sulfuric acid comprising the steps: a) recovering a gas stream from a sulfuric acid recovery furnace; b) directing said gas stream to a particulate scrubber; c) injecting ozone into said gas stream in said particulate scrubber; d) scrubbing oxidized NO_(x) in said particulate scrubber; e) directing said scrubbed gas stream to a gas drying tower; f) directing said dried, scrubbed gas stream to a catalyst bed to convert sulfur dioxide present in said dried, scrubbed gas stream to sulfur trioxide; g) directing said gas stream containing sulfur trioxide to a sulfuric acid absorption tower; and h) recovering sulfuric acid.
 17. The method as claimed in claim 16 wherein said ozone is injected into said gas stream in a molar ratio of about 0.5 to 3.0 ozone to nitrogen oxides.
 18. The method as claimed in claim 16 wherein said ozone is injected at a pressure of up to 25 psig and ozone is up to 10 weight percent in oxygen.
 19. The method as claimed in claim 16 wherein said gas stream contains sulfur dioxide, nitrogen oxides, fly ash, particulates and other acidic contaminants.
 20. The method as claimed in claim 16 wherein said ozone converts said nitrogen oxides to N₂O₅ and nitric acid.
 21. The method as claimed in claim 16 wherein said particulate scrubber removes said fly ash, particulates, N₂O₅, nitric acid and other acidic contaminants from said gas stream.
 22. The method as claimed in claim 16 wherein said gas dryer removes water from said gas stream.
 23. The method as claimed in claim 16 wherein said catalyst bed comprises one or more catalyst beds.
 24. The method as claimed in claim 16 wherein said catalyst bed contains V₂O₅.
 25. The method as claimed in claim 16 wherein environmental scrubber uses a caustic scrubbing solution.
 26. The method as claimed in claim 16 wherein said gas stream is at a temperature of 100° C. or less.
 27. The method as claimed in claim 16 further comprising injecting oxygen into said sulfuric acid recovery furnace.
 28. The method as claimed in claim 16 wherein said ozone contacts said waste gas stream in a disengagement zone of said particulate scrubber
 29. The method as claimed 16 comprising washing said waste gas stream in said particulate scrubber.
 30. The method as claimed in claim 16 wherein primary particulate wash, contacting with ozone and final particulate wash and nitrogen oxides scrubbing are all performed in at least one vessel. 